Control system



May 27, 1952 P. s. DlcKEY ET AL CONTROL SYSTEM Original Filed Jan. 50, 1946 AND ` ATT ORN Patented VMay 27, 1952 UNITED STATES TENT OFFICE CONTROL SYSTEM Paul S. Dickey, East Cleveland', and Anthony J. Hornfeck, Lyndhurst, Ohio, assignors to Bailey Meter Company, a corporation of Delaware The present invention relates to measuring and/or control systems, particularly of the elec--v tronic circuit type. A variable condition, quantity, quality, position or other variable which may be represented by an electrical resistance value may be continuously and instantaneously compared to a desired value and the deviation measured or used in control. The measurement so obtained may be used to effect a control of the same'or another variable which may or may not contribute to the magnitude or change inmagnitude of the variable being measured.

Specically our present invention provides improvements in an electronic measuring and controlling circuit allowing a control standard value to be established in accordance with a predetermined time program. Thereafter the deviation ofthe actual value of the variable from the desired or Vprogrammed value is determined and indicated and may be used inr the control.

A furtherl object of our present invention is a continuous subtraction of values which in eiect is the same as the deviation between one variable and a predetermined standard.

Still another object is the incorporation in such a measuring and controlling system of a telemetric circuit' through whose agency the measuring and controlling circuit may be located at a considerable distance from thek point of control or from the point of actual variation in the variable being measured or under control.

We have chosen to illustrate and describe our invention in connection with certain basic electronic measuring circuits as representative only and not limited thereto. In general, we describe ourinvention in connection with a phase sensitive A.C. bridge network including a resistance thermometer. We illustrate and describe a telemetric circuit of the movable core transformer type and incorporate the measuring control in connection with an electric furnace.

In the drawing the single gure is a schematic showing; of a measuring and control circuitv in accordance with our invention applied to an electric furnace.

Referring now to the drawing, we indicate at I` a phase sensitive A.C. bridge having fixed resistor armsV 2, 3 and 4. The fourth arm of the bridge I is a resistance-element 5 locatedvin an electric vfurnace 6 and sensitive to the temperature'thereof. For balancing the network we provide an adjustable resistance 'Ihaving a movable contact arm 8 for proportioning the resistance "I between the arms 3 and 4.

For positioning the contact arm 3 we pro- 5 Claims. (C1. 23S-461) A.C. source Ill, 'which alsoprovides A.C. supply to the bridge I through a transformer I5.

Preferably the bridge arm 5 is a vplatinum reistance measuring element. V1lhe conjugate corners of the bridge I are connected to an amplier I6 and motor control Il for the motor 9. For an understanding of a phase sensitive A.C. bridge for measuring the resistance of the leg. 5 subjected to temperature of the furnace 6 refer`- ence may be had to the Ryder Patents 2,275,317 and2,333,393. The conjugate voltage supplied to the amplifier It assumes a balance or unbalance and a phase-relation relative to the supply .voltage dependent upon the magnitude and sense of the unbalanced condition of the bridge I. The amplifier I6 selectively controls a pair of motor tubes I3 and I3. The tubes I3, I9 control the amount and direction of unbalance of saturable core reactors 20, 2l for directional and speed control ofv the capacitor-run motor 9 adapted to position the arms 8, l0.

The motor 9 is of an A.C. type having windings 22 and 23 ninety electrical degrees apart and also having a capacitor 2d. When alternating current flows directly through one of the windings and simultaneously through the other winding in series with the capacitor, the motor rotates in predetermined direction and at aspeed determined by the extent of unbalance of the. saturable core reactors 2l?, 2|. It is not necessary to go into greater detail as to the construction and operation of the amplier I6 and' motor control circuit I', as reference may be had to the above mentioned Ryder patents.

So far we have described a knowncircuit arrangement forcontinuously measuring the temperature of the furnace 6 and providing a visual indication thereof upon the index I l and a continuous record upon the chartr I2. Thebalanceable networkl provides a continuous measurement without intermittent feeling devices, galvanometers, or other moving` parts except for the power motor 9, which isselected to provide ample power to position the. indicating-recording arm I0y and the balancing contact 8. Preferably and usually the elements I., It, I'I', 9 are located in the casing containing the `indicator and recorder and may be mounted on a panel board or at any desired central control location. Such a location may be adjacent to or remote from the furnace 6.

In our present invention additionally we p-rovide a deviation network 25 for continuously comparing the actual value of the temperature or other variable with a desired or standard value. The network 25 continuously determines the deviation, if any, between the actual and the desired value of the variable or variables and utilizes such information in continuously visually advising the extent of deviation or as a basis for the control of the same or another variable which may or may not contribute to the change or maintenance oi the original variable being measured.

Specifically, the network I, |6, I1 is sensitive to the temperature of the furnace 6 at the resistance arm 5 for continuously determining such temperature and indicating it upon the index I and recording it upon the chart l2. Simultaneously the motor 9 controls the position of a contact arm 26 along a slidewire potentiometer 2 of the deviation network 25. The deviation network preferably is located in the casing with the recorder and is mechanically close to the motor 9.

In this preferred embodiment, we desirably continuously compare the actual temperature at the element 5 with a desired or standard temperature to be maintained within the furnace 6 and illustrate the deviation network 25 as containing a time cycle or program mechanism 28 establishing the desired or standard temperature which may be uniform over the 24 hour period or may be programmed to have a different temperature at different times of the day.

The program mechanism 28 includes a time motor T driving a program cam 29. A fulcrumed roller arm 3U is continuously positioned by the program cam 29 and in turn positions a magnetic core piece 3l relative to windings 32, 33, 34. The elements 3|, 32, 33 and 34 constitute a movable core transformer wherein the primary winding is continuously energized across an A.C. source. The position of the core piece 3| in relation to the windings determines the inductive relation between the primary 32 and the secondaries 33, 34, and thereby the potential relation between the windings 33, 34.

Interposed between the windings 33 and 34 is a potentiometer or resistance 35. The elements 2, 33, 35 and 34 are connected in series loop with Calibrating resistances 33, 31. As mentioned, the loop circuit receives energization inductively from the primary 32 through the coupling provided by the magnetic core piece 3|. Across the loop are conductors 39 and 39 connected respectively to Contact arms 2B and 49. The arrangement is such that the conductors 38, 39 divide the loop into two portions which may or may not be balanced insofar as sense and magnitude of potential are concerned. If the two portions of the loop are in balance, then the conjugate conductors 38, 39 are electrically null as to magnitude or sign of potential. If an unbalance occurs between the two portions of the loop, then a potential exists between the conductors 39, 39 of a sense and magnitude determined by the direction and extent of imbalance.

Assume first that the loop is in balance. No potential exists between the conjugate conductors 38, 39. If the contact arm 26 is moved in one direction along the resistance 21, the loop becomes unbalanced and a potential is set up between the conjugate conductors 39, 39 of a sense depending upon the direction in which the contact 25 had been moved.

Assume again that the loop is in balance. If the core piece 3| is moved in one direction, relative to the windings 32, 33 and 34, then the inductive balance between the windings is disturbed, and either the winding 33 or the winding 34 is to a greater extent under the control of the core piece 3|, and thus receives a greater inductive effect from the primary 32. A potential is established between the conjugate conductors 38, 39 whose sense is determined by the direction of movement of the core piece 3| and whose magnitude is determined by its extent of movement.

This analysis is, of course, on the assumption that the contact arm 4Q is not moved from its previous position along the resistance 35, and that a contact arm 4| is not moved from its position along a resistance 42.

In general, the potential condition in the conjugate conductors 38, 39 is representative of the direction and extent of deviation of the actual temperature at the element 5 as compared to the desired temperature as represented by the position of the core piece 3| relative to the windings 32, 33 and 34.

Such manifestation of coincidence or of deviation may be utilized in a control of the furnace 6 to eliminate deviation and to maintain the temperature at the element 5 in correspondence with the desired standard which may be a uniform standard or a programmed standard. Obviously the cam 29 may be shaped to dictate a desired program varying with time. If the cam 29 is circular then the core piece 3| retains its uniform coupling of the windings 32, 33 and 3d establishing a uniform temperature standard for comparison with the actual temperature.

We have indicated that the contact arm 40 is manually movable along the resistance 35 from a zero position in one direction plus and in the other direction minus. Such indications are of deviation between the actual and a desired value of temperature. The predetermined shape of the program cam 29 may be useful under different conditions which would indicate that a constant deviation of a few degrees in one direction or the other is desirable for a particular condition of operation. For example, if the furnace 6 is used to heat treat metal objects, then the general program (as arranged on the cam 29) of bringing the furnace 6 up to temperature and maintaining it at one or more preselected temperatures over given periods of time might hold true for the particular metal being treated. However, if one batch of castings are large compared to another batch of smaller castings, then while the program may hold constant for the two batches, still one might desirably be at a temperature of 10 above the other throughout the program. Such a control condition may be established by manually moving the Contact arm 40 along the resistance 35 in either a plus or a minus direction depending upon whether the actual temperature is to deviate a constant amount above or a constant amount below the standard established by the position of the core 3| relative to the windings 32, 33, 34.

Graduations adjacent the resistance 35 may be in degrees temperature or in percentage or otherwise. There is a uniform proportionality between the motion of the slidewire contact 23 and motion of the transformer core 3|. With this linear or straight line relation the deviation determine'd byA fthe' setting.- of "l the pointer leva-long the resistance-:135s: isv fa predictable and uniform measure 'of' 'devi-lation. 'With an adequate 'contrl systemfunctioning sensitiv-erto the potentiai condition of 1 the f conjugate conductors r38', 39v the relation Iof the elements '43, 315 Apredetermines'a constantdeviationfor dink-:renceA betweenthe: actualfvtemperature and the desired temperature irrespective as Y to whether the 'desired temperatureV is a uni-form f or constantV temperature orv is one varying-with timein predetermined-manner.

In the embodiment being described we provide an'el'ectricalrcontrol of the heat input of the resistor t3 lto the electric 'furnace 5. We have shownin this connection a power controller 43 which forms no part oi' the vpresent invention. This may beaGeneral Electric Reactrol described in: Patents 2,266,559, 2,285,172, 2,285,173 and 2,383,806,0r-*anyother adaptable power controllerfor the resistor I3. Our invention applies tov the-power controller 43,the establishment-of an-electrical value, through an amplifier 4f if necessary, responsive or sensitive'to the potential `condition ofthe conjugatey conductors 38, 39

and thereby sensitive to the deviation networkl if.

25 continuously comparing the actual temperaturevat the element-5 with a predetermined or desired'temperature. The output of the power controller t3 (input to the furnace 6) is in proportion toY deviation or unbalance condition exista" ing-across 3B, 3,9.

A distinction 4of this'electrical Acircuit is that while the deviationnetwork 25 is a balanceable network itisnot balanced "by means of movement'of t-hecontact 40 overl thepotentiometer 35 perature in the furnace .6, effective upon the resistance arm 5, results in a positioning of the contact arm -26 alongthefpotentiometer 2T to a position representative of the new temperature. This produces an unbalance in theloop with a resulting potential across the conjugate conductors '38, 39 whose direction and magnitude is related tothe direction and magnitude of movement of the-arm2l'il fromfthe balanced position. The potential condition ci theconductors 3S, Si?

iseffective uponthepower controller 43 for ini" creasing or decreasing the electrical energy through the heater I3 to restore the temperature at the element 5 to predetermined desired value. The loop of the deviation network 25 is, therefore, not returned to a balanced condition until the temperature at the element 5 returns to the desired standard value with consequent return of the arm 26 to its previous position along the resistor 21.

It will be apparent that the deviation loop may be thrown out of balance by a movement either of the arm 26 or of the core 3I and that either of such movements will result in an adjustment of the heater I3 for change in temperature to which the element 5 is sensitive.

For example, if the system is in balance and the desired temperature exists at the element 5, then the time program cam 29 may call for a new temperature through a movement of the core 3| This unbalances the deviation loop, resulting in Sal 6 an adjustment of `thefheater ,I3 :andi yechange in temperature tof whichl the element issensitive.

Ii theheatcr t3' brings suchV temperature to the. newly desired' value, the: loop.l iszfagain .balancedbut'rat a--new positionfofthe arm zwand, ofv the corerSIr.

'In such :a system f asV We vhave. "described there. will exista:` .thermal lag fromfthe. timeA archange in electricrenergy iszimade: throughthe `resistor I3 and .consequent change in temperature.. tov which thev element 5J is. sensitive. Thus vthere will` exist' a lag between ythe. time. yofjmovement of :the-:corer'l :and of the attainment ofVv aznew position Yofthe farm 26 suicient vtonbalance.l 'the deviationloop- If the Vprogram cam f 29 isy tout-.z to a spiralsor uniform risecharacteristic, then a uniform time lag lwill exist between the vtemperature called for: byft'he'positionf-of the'p1unger'3I and the' temperature actually existing- Vas indicated by thepositionof the'arm 26. The steeper the 4rise of the camr29vthe-^greater will be the deviation between the two representations of temperature: That is, if the camrise is veryl steep there will be a greater span intemperature between the temperature desired vas indicated byposition of the core 3| .andthe actual .temperature asindicated by the position of the contact arm 26.

- This in simple language vbecause the. heating effect of the furnace can not keep up'with' the demand for change in temperature.

Either the thermal lag of the heating system or theftime lag between the movement of the plunger 3| and movement of the. contact 26 wiil produce the deviation between the Y'desired temperature and the actual temperature. Such a deviation can be ascertained for any given' installation or condition of operation `and can be compensated for by movement of the contact' 4t along the resistance 35. In other wordsif it is ascertained on a given' 'furnace installation that during normal operation there is a thermal lag of so many degrees in changing temperature, a certain amount of compensation can be vtaken care Yof through the elements 40, 35. 'Ihe'same is true in regard'to a follow-lag on a. gradually changing temperature Yprogram of thecam 23. It is appreciated that. a gradualchange in temperature in one direction followed by a gradual change in the other direction may mean' a plus deviation for one period of time, followed by aminus deviation. This could not be compensated for by a single adjustmentof the arm in relative to the resistance 35. However, such conditions are usually not of the same extent or duration and the one of major consequence. may be compensated for while the other condition may be neglected.

It is possible to incorporate in the shape of the cam 26 corrections for both positive and negative deviations after the characteristics of the system have been explored and studied.

'i Thus the shape of the cam 29 may readily be changed to incorporate changes in desired program, as well as to incorporate corrections for deviation between the actual and the desired temperature, which deviation may result from thermal lag of the heating system or from mechanical and/or electrical follow lags.

This application constitutes a division of our copending application Serial No. 644,267 iiled January 30, 1946, nowv Patent 2,491,606 dated December 20, 1949.

What we claim as new, and desire to secure by Letters Patent of the United States, is:

1. Temperature control means for a furnace or the like comprising in combination, a furnace, heating means for said furnace, a controller for said means, a resistance thermometer subject to the temperature of the furnace and including a motor actuated to indicate the temperature, a deviation bridge including a pair of resistors each having a movable contact element, a conjugate conductor connecting said movable contacts for possible division of the bridge into two equal sections, means to induce alternating current into each section to energize the same comprising a dual secondary transformer having one secondary connected in each section, a primary and a movable core element to inversely control the coupling of the secondaries to the primary, means connecting said motor to actuate one of said movable elements, program means to move another of said movable elements to establish desired temperature standards changeable with time, means responsive to unbalance current in said conjugate conductor for actuating said heating means controller, and the remaining movable element being manually adjustable to determine the degree of deviation of the furnace temperature from the programmed temperature and independent of any change in position of the controller for the heating means.

2. The combination of claim 1 in which the last mentioned movable element is a contact movable over one of said resistors, a shunt for said resistors and manual means to adjust the value of said shunt.

3. The combination of claim 1 wherein the movable element which is positioned by the program means is the movable core of said transformer.

4. Control means for regulating a variable condition of a furnace or the like comprising in combination, a furnace, regulating means of the variable condition in the operation of the furnace, a measuring system for the variable and including a motor actuated to indicate the value of the variable condition, a deviation bridge including a pair of resistors each having a movable contact, a conjugate conductor connecting said movable contacts for possible division of the bridge into two equal portions, means to induce alternating current to each portion to energize the same comprising a dual secondary movable core transformer having one secondary connected in each portion and having a primary and a movable core to inversely control the coupling of the secondaries to the primary, means connecting said motor to position one of said movable contacts', program means to position the movable core to establish desired standards of value of the variable conditions with time, means responsive to unbalance current in said conjugate conductor for actuating said regulating means, and the remaining movable contact being manually adjustable to determine the degree of deviation of the variable condition from the programmed value and independent of any change in position of the regulating means for the variable condition.

5. Control means for regulating a variable condition of a furnace or the like comprising in combination, a furnace or the like having a condition variable with and during operation thereof, regulating means of the variable condition, means continuously responsive to the value of the said variable condition, an electrical deviation bridge including a pair of resistors each provided with a movable contact, a conjugate conductor connecting said movable contacts for possible division of the bridge into two equal portions, means to induce alternating current into each portion to energize the same comprising a dual secondary movable core transformer having one secondary connected in each portion and having a primary and a movable core to inversely control the coupling of the secondaries to the primary, means connecting the value responsive means to position one of said movable contacts, program means to position the movable core to establish desired standards of value or" the variable condition with time, means re sponsive to unbalance current in said conjugate conductor for actuating said regulating means. and the remaining movable contact being manually adjustable to determine the degree of deviation of the variable condition from the programmed value and independent of any change in position of the regulating means for the variable condition.

PAUL S. DICKEY. ANTHONY J. HORNFECK.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 1,795,753 Boon Mar. 10, 1931 2,025,542 Lugar Dec. 24, 1935 2,220,028 Smith Oct. 29, 1940 2,406,221 Hornfeck Aug. 20, 1946 2,412,263 Hartig Dec. 10, 1946 2,491,606 Dickey et al Dec. 20, 1949 

